Sensors TOC-625, TOC-630 Installation And Operation Manual

IAQ

CO

CH4

NO2

LPG

C O2

H2

O2

C2H6O

TOC-625-630

Multi-Channel Sensor Controller

Installation and Operation Manual

Version 3

Page 1 of 25

www.sensors.ltd.ukA Division of International Gas Detectors

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INDEX

Who should read this manual.

This manual is intended for use by trained installers of gas detection systems who are technically
competent and have all necessary tools to undertake installation and maintenance on this type of
equipment.

Failure to install and maintain the equipment properly can render the detector ineffective.

You should not undertake any of the procedures in this manual if you do not have access to the
correct equipment, have not undertaken training on this or similar equipment or are not technically
qualified to install this equipment.

Calibration gases and test equipment is available from Sensors.

Page 2 of 25

Page

3
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10
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13
14
14
15
15
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17
17
18
19
20
21
21
22
23
23
24
25

CE Declaration
Gen Specifications
Main electrical Connection Points
Controller Overview
User Actions Day to Day Operation
Display Access and Menu Operation
Menu Overview
Putting into Service

Adding Detectors or Nodes
The FIND Command
Alarm settings

Calibrations

Cable checks and Warm Up Sequence
Supplied Set up
Channel Setup Overview
Relay Connections
Analogue Output (mA option)
Analogue Output (Volts Option)
Analogue Output Test
Putting into Service Summary

Alarm Level Setup
Alarm Type Setup
Alarm Relay
Alarm Summary

4-20mA Output Zero Function
4-20mA Output Calibration Function
Detector Zero Function
Detector Calibration Function

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EC Declaration of Conformity

Issuers name and address:

Oliver IGD Limited of
4a Pepper Rd
Stockport, SK7 5BW
United Kingdom

Declares that the product listed as:

TOC-625

Single or Multi-Channel Detector Control Panel

Issued on: At Oliver IGD Limited, Stockport, SK7 5BW , United Kingdom

Notified Body For ATEX
and/or QAN:

Sira Test & Certification Ltd
Hazardous Area Centre,
Rake Lane
Eccleston,
Chester,
CH4 9JN.
United Kingdom

Oliver IGD Limited operate an
independently assessed ISO9001:2008
Quality Assurance System and ATEX QAN.

Quality Assurance Certificate Number

023827

Quality Assurance Notification Number

SIRA 02ATEX M174

Signature:

Name Andrew J Collier M.I.O.D

Position: Managing Director Date: 5.October 2011 Declaration Ref: TOC-625-DEC-1

Declaration of Conformity in accordance with EN ISO/IEC 17050-1:2004

Testing Agency:

CASS Industries Limited
Blackbrook Trading Estate
Weybrook Rd
Levenshulme
Manchester
M19 2QD

Are in conformity with the provisions of the following European Directive(s) when installed, operated, serviced and maintained
in accordance with the installation and operating instructions contained in the product documentation.

And that the standards and/or technical specifications referenced below have been applied or considered.

2004/108/EC EMC Directive
2006/95/EC Low Voltage Equipment Directive (note not applicable to 24V DC Powered Versions)

EN 61779-1:2000

EN 50271:2001

Technical File Reference

Electrical apparatus for the detection and measurement of flammable gases, general
requirements and test methods.

Electrical apparatus for the detection and measurement of combustible gases, toxic gases or
Oxygen: requirements and tests for apparatus using software and or digital technologies.

Excluding requirements for SIL

T625-TF9

CO

H2S

CO2

SO2

NO

NO2

CH4

TOC-625TOC-625

SY

STEM CONTROLLER

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Page 3 of 25

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141

79

18

136

196

24

30 30 30 50

84

PANEL MOUNT VERSION (CLAMP)

201

PANEL CUT OUT

PANEL CUT OUT

30

122

108

23

14

REAR VIEW WALL MOUNTING
POINT DETAILS 4.5mm
SCREWS

FRONT VIEW

BOTTOM VIEW

REAR VIEW

SIDE VIEW

4 HOLES DIA 20mm

4 REAR ENTRY
KNOCK OUTS
20mm DIA

GAS DETECTION S YSTEM

T

O

C -625

SELECT

FAULT

POWER

ALARM

ALARM

112

2

Optional Panel Mounting Kit
PN 5686401

Optional Battery Backup Kit
PN 5686601

Note this module uses the
same style enclosure as the
TOC-625 and houses
batteries and charge control.
It is usually mounted below
the TOC-625 and is supplied
with all required connectors.

Physical Details

Standard Specifications

Power

Construction

Display

Outputs

Other I/O

Inputs

Temperature

Humidity

Sealing

110/230V AC 50/60Hz 30W Standard
24V DC Option

ABS

2 Lines x 8 Digit LCD Display
Multi-Colour Backlight (Red-Alarm, Yellow-Fault, Blue-Normal)

2 off SPCO Relays 4A Non-Inductive
User Configurable
3 off 4-20mA Linear Outputs
User Configurable

Sounder 80dB @ 100mm (Mutable)
RS485 Port Modbus

8 off Addressable Series Detectors or I/O Modules

-5 to 55 Deg C

0-95% RH Non-Condensing

IP54

Do not exceed listed ratings.

Failure to observe interface

ratings and environmental

operating conditions may have

an adverse affect on the

controller.

Page 4 of 25

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Electrical Details Figure 1

Front View Cover Open

L N Enc nc

Mains Power

Connector

110/230V AC 50/60Hz

+24V DC
0V DC
mA Sig 1
mA Sig 2
mA Sig 3

Analogue Output Interfaces

Note as standard mA

outputs are set. These

can be re-configured

as 0-10V signals

Detector I/O Interface

0V DC A B 24V DC

Detector

I/O Node

Relay 1
Relay 1

24V DC
Input 1

Relay 2
Relay 2

Input 2
0V DC

Connect up to 8 addressable
devices. These can be Gas
Detectors or by using the
available I/O Nodes any 4-20mA
Device such as pressure or
temperature transmitters, read
these back to the control panel
as any other detector and set
alarms as required.

Connect to detectors and nodes
using 4 core 1.5mmSQ CY style
cable or FP200 style cable as
appropriate. Cable screens
should be terminated as
indicated

Each I/O Node counts as one
device and can be used to
interface to analogue devices
and provide additional relay
outputs where they are
needed to control items such
as beacon-sounders,
solenoids or interfaces to fire
panels. Depending on
loading external power may
be required.

Gas detectors count as one device,
there can be any mix of gas detector
types on the highway. For example
Flammable Gas Detectors, Carbon
Monoxide, Oxygen etc.

RL

1

RL

2

Normally Closed
Common
Normally Open

Connections
common to each of
the two relay outputs

0V DC
A
B
24V DC

RS485 Modbus
Comms Port

SCRN 0V DC A B 24V DC

SCRN 0V DC A B 24V DC

SCRN 0V DC A B 24V DC

SCRN 0V DC A B 24V DC

1

2

3

4

Page 5 of 25

NOTE

Main power connections should only be made by a qualified electrician. Mains power should be fed via a fused

spur.

The following information shows the main electrical connection points labelled as points 1, 2 and 3. These

points are referred to in the manual supplied. When installing ensure you have the full manual available. This

page is also supplied inside the TOC-625 enclosure as a quick reference for site engineers. If you do not have

the full manual a copy is available on the Sensors website at www.sensors.ltd.uk

www.sensors.ltd.ukA Division of International Gas Detectors

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GAS DETECT ION SYSTEM

TOC -625

SELECT

FAULT

POWER

ALARM

ALARM

112

2

Controller Overview

Colour Backlit LCD Display
Flashes Red on alarm
Flashes Yellow on Fault Detection
Blue during menu operation
Note the back light is off in normal operation and
is on during an alarm, fault detected or when editing
or checking.

Internal Sounder 85dB
Sounds on alarm 1 or 2 activation
and can be muted

Alarm Indicator LED (Red)
Flashes on Alarm Level 1
Continuous on Alarm Level 2

Fault Detected
Indicator LED (Yellow)

Power LED (Green)

Selector Button

WARMUP

600s

On initial power up the backlight will perform the
following cycle:

Backlight cycles: green-yellow-red

The display then shows:

Software Version
Software checksum and date
Connected sensor info

Finally a countdown starts to enable connected
sensors to stabilise prior to normal operation.

Typical display during warm up

Page 6 of 25

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User Actions....Day to Day Operation

1=FLAM

10% LEL

1=FLAM

alarm 1

1=FLAM

FLT UND

To access the display click the button

In Alarm Condition

In Fault Condition

Channel
Number

Channel
Number

Channel
Number

Channel
Gas Type

Channel
Gas Type

Gas or Reading
Type

Current Channel
Reading

The back light turns on making
it easier to see the channel
information. Note that each
channel will be displayed in turn
as indicated by pressing the
button.

The back light will flash red and
the display will indicate which
alarm level and which channel
is in alarm. The sounder will
also activate. Pressing the
button will silence the sounder.
If the gas is still breaching the
alarm threshold it will not be
possible to reset the alarm

Once fully installed the TOC-625 controller will continuously monitor connected gas detectors and

sensors and compare current values with any set alarm thresholds. The display will cycle to display

each channel in turn. Normally the backlight will be switched off.

In the event of alarm or fault, CALL FOR SERVICE.

The owner operator is not usually a gas engineer or competent person

as defined by Health and Safety guidelines. If there is any doubt call

your service company and get it checked.

SELECT

FAULT

FAULT

POWER

POWER

ALARM

ALARM

112

2

In alarm mode the RED
alarm led will either be
flashing for alarm level 1 or
solid for alarm level 2. The
bottom line of the display will
indicate:
Alarm 1
Alarm 2
Alarm 1&2

In FAULT mode the Yellow fault led
will either be on. The bottom line of
the display will indicate as follows:

Alarm Level

Page 7 of 25

FLT COM

FLT SEN
FLT OVR
FLT UND

communication
error to sensors
Sensor Error
Sensor Over Range
Sensor Under Range

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1=FLAMM
10% LEL

á 0

PASSWORD

â 0

PASSWORD

á 0

PASSWORD

áá 50
PASSWORD

á 50

PASSWORD

dec
PASSWORD

done
PASSWORD

inc
PASSWORD

cancel
PASSWORD

To access the display press the button for 1-2 seconds

Data entry and menu selection using the password entry as an example.
To access the menu system press the button until the message
“Release button and enter password”
message is displayed.

Channel
Number

The up arrow indicates
that the indicated password
number will increment at
each button press.

Gas or Reading
Type

Password Number You are
Entering

Current Channel
Reading

The back light turns on making
it easier to see the channel
information. Note that each
channel will be displayed in turn
as indicated

If the button is pressed twice in a
short time then two up arrows
appear to indicate auto increment.
Now just keeping the button
pressed increments the reading.

To end Auto Increment mode
release the button for more than
1s.

Note auto Increment works in
menu selection as well as data
entry to speed up menu
selections. Make sure auto
increment is off when making
selections.

With one arrow displayed
keep the button pressed
and the following menu
options appear.

Release button to select. The arrows
now indicate down to show you are
decrementing the number

Release button to select. The arrows
now indicate up to show you are
incrementing the number

Release button to select and enter (in
this case) the password.

Release button to select and cancel
the action.

Page 8 of 25

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Toc-625 Menu Overview

á 0

PASSWORD

find

1 of 11

zero

1 of 8

edit add

2 of 11

cal

2 of 8

output 2

8 of11

disable

5 of 8

about

7 of 8

test add

3 of 11

test rly

4 of 11

Check

5 of 11

Fix

6 of 11

alarm 1

3 of 8

output 3

9 of11

contrast

6 of 8

output 1

7 of 11

alarm 2

4 of 8

usr menu
10 of 11

exit

8 of 8

exit

11 of 11

50

100

Engineer Menu Options

User Menu Options

Provides access for
control panel set up and
diagnostic functions

Provides access for
maintenance functions

Use this option to
FIND connected
devices.

Use this option to
ZERO connected
devices

Use this option to
change the address of
a connected device

Use this option to
CALIBRATE
connected devices

Use this option to test
that connected
devices communicate
correctly

Use this option to test
The relay outputs and
audio vis devices on
the controller.

Use this option to trun
the auto Check
function on a detector
channel.

Use FIX to automatically
correct any channel
errors detected during
CHECK

Use this option to set
ALARM 1 level and
action

Use this option to test,
zero or calibrate
analogue output 1

Use this option to set
ALARM2 level and
action

Use this option to test,
zero or calibrate
analogue output 2

Use this option to
disable a channel

Use this option to test,
zero or calibrate
analogue output 3

Use this option to set
the screen contrast

Use this option to view
software version etc

Use this option to
move to the user
menu

Use this option to
EXIT to normal
operation

Use this option to
EXIT back to normal
operation

Page 9 of 25

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It is recommended to follow the set up sequence below when configuring and installing a control
panel from new.

Follow the cable commissioning procedure T625-700-920.PDF
if you don't have a copy of this download it from www.sensors.ltd.uk

Perform a sensor FIND and automatically install detector data. Engineers Menu .... Find Option

(note panels are usually supplied pre-configured so this
many not be necessary, check shipping documentation)

Set the sensor channel alarm levels. User menu ... Alarm Setup Options AL1 and AL2 for each
channel.

(note panels are usually supplied pre-configured so this
many not be necessary, check shipping documentation)

Allow the system to run for at least a few hours then:

Zero each connected detector. User Menu ZERO

Calibrate each detector. User Menu CALibrate

EXIT to normal operation and check alarm operation by applying calibration gas and observing
alarm activation.

Make sure all components are communicating correctly. Engineers menu TEST ADD option.

find

1 of 9

alarm 1

3 of 8

alarm 2

4 of 8

zero

1 of 8

cal

2 of 8

test add

3 of 9

Putting Into Service

Note that this product should be supplied via a fused spur. Ensure cables used are suitable for both
their intended area of operation and load capability. This product should only be installed by a
competent person.

Page 10 of 25

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This Section Follows the Sequence for Putting Into Service to Describe the Menu functions

Figure 1 shows the electrical connections to the Tocsin 625 controller.

Mains power is supplied via connector 2 and should be from a fused spur. This connection should be

made by a qualified electrician.

Cable Checks

Detectors are interfaced to connector 3. It is important to ensure that all connected devices are wired in

accordance with the details supplied in Figure 1 and each relevant detector or I/O node manual.

Cabling should be rigorously checked to ensure there are no cross overs or shorts before any power is

applied. If in doubt follow the cable check procedure listed in “Cable checks T625-700-920.PDF”.

Relay outputs and analogue outputs are indicated on Figure 1, connector 1 and RL1, RL2 respectively.

These should be left unplugged at this stage.

WARMUP

600s

With power applied the system should undertake its power up sequence and

then commence a warm up period. The warm up period is there to allow

connected detectors to stabilise before operation. Note that certain detector

types, Oxygen sensors in particular may take up to 2 hours to fully stabilise.

During the warm up period check that each connected detector or device has power and

communication. The following diagram shows the three main terminal PCB types for detectors and I/O

interface nodes and the relevant check points.

Toc-625
Addressable I/0
Port 3

24V DC

B
A

GND

T106P Pellistor
Flammable Gas
Detectors

T107 Addressable

I/O Node

T102/3 Toxic

IR/Oxygen Comms

Module

ZERO

FAULT

CAL

360

CHASS

CHASSCHASS

24V DC

24V DC24V DC

B

BB

A

AA

GND

GNDGND

mA

P Y W

mA+360CONC0V mA-

Toc-625

Earth Point

Sensor

This LED flashes to
indicate power and
comms. With no
comms LED is on
constantly

This LED flashes to
indicate power and
comms. With no
comms LED is on
constantly

This LED flashes to
indicate power and
comms. With no
comms LED is on
constantly

Warm Up Period

Page 11 of 25

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With sensors connected and after the TOC-625 controller has completed its warm up the operating

system will go to normal operation mode.

Normal Operation

In normal operation mode the TOC-625 communicates to each detector or node in turn and displays the

data on screen. In normal mode the back light will switch off. Pressing the button once will activate the

back light, each button press then cycles the display through each channel.

For example a three channel system with a Flammable gas detector, a Carbon Monoxide Detector and

an Oxygen detector would read as:

1=FLAM
0% LEL

2 = CO

0 ppm

3 = O2

21% VOL

Channel Number Gas Type

Reading Units

Systems supplied as a complete ‘set’ or order will normally have been set up at the factory during

final test. A set up report will be supplied with the controller to indicate how the control panel has

been configured. Where a client advises a particular alarm set up requirement this will be

incorporated. If no alarm set up is requested then systems will be shipped with alarms at 20% and

50% of detector range, rising latching alarms, for Oxygen sensors by default alarm 1 will be at 19%

and alarm 2 at 18% falling non latching alarms. For example the report the three channel discussed

above would read as follows:

Channel 1

Address
Gas
Range
AL1
AL1 Type
AL1 Relay
AL2
AL2 Type
AL2 Relay
Analogue
Output
Channel

Channel 2

Address
Gas
Range
AL1
AL1 Type
AL1 Relay
AL2
AL2 Type
AL2 Relay
Analogue
Output
Channel

Channel 3

Address
Gas
Range
AL1
AL1 Type
AL1 Relay
AL2
AL2 Type
AL2 Relay
Analogue
Output
Channel

4101
Methane
100% LEL
20%
Rising Latch
1
50%
Rising Latch
2
C1

4102
CO
100 ppm
35
Rising Latch
1
55
Rising Latch
2
C2

4103
Oxygen
25% Vol
19%
Falling
1
18%
Falling
2
C3

Sales Order: S/36981 Client: A.N Other TOC-625 Set Up Report

Supplied Set Up

Page 12 of 25

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Channel 1

Address
Gas
Range
AL1
AL1 Type
AL1 Relay
AL2
AL2 Type
AL2 Relay
Analogue
Output
Channel

4101
Methane
100% LEL
20%
Rising Latch
1
50%
Rising Latch
2
C1

Channel Set Up Overview

The Channel Number as indicated on the TOC-625 display

The gas which this channels detector measures
The measurement range for this channel

The threshold limit for alarm level 1

The threshold limit for alarm level 2

Alarm Action (in this case the alarm latches once the threshold is exceeded

Alarm Action (in this case the alarm latches once the threshold is exceeded

Which relay activates when alarm 1 threshold is exceeded

Which relay activates when alarm 2 threshold is exceeded

Which analogue output relates to this channel.
Note there are three analogue outputs available on the TOC-625

The detector address for this channel. This address will be marked
on the cover of the detector itself

Using channel one as an example the following diagram explains a typical channel set up.

If the control panel has been shipped pre-configured then once correctly connected the system will be

operational. The controller should correctly cycle through each channel with no indicated errors.

Relay Test

The alarm relay outputs can now be connected (if they are being used). The relay outputs can be

forced on and off using the ‘test relay’ function (TEST RLY).

test rly

7 of 9

release

From Normal Operation press the function button until the display

alters to show ‘release button.

The system now requests a password. Enter 50 to enter the

Engineer Menu.

Press the function button until option 7 of 9, TST RLY is displayed.

Now hold down the button until prompted to release.

The display will now indicate Relay 1 On (and relay 1 should be

energised. At each press of the button each physical output is

energised in turn as indicated on the display as:

á 50

PASSWORD

test rly

7 of 9

tst rly
release

RELAY 1

ON

RELAY 2

ON

BUZZER

ON

LED PWR

ON

LED FLT

ON

LED AL

ON

BACK RED

ON

BACK GRN

ON

BACK blu

ON

Each button press cycles through

the displays as listed. To exit, press

and hold the button until prompted

to release

Page 13 of 25

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Relay Connection

Analogue Outputs (mA)

0V DC

24V DC

~

~

A1

A1

A2

A2

Example fit protection
diodes when switching
external DC loads.

Example fit protection
supressors when switching
external AC loads typical
device Farnell Ref 1438460
(0.22uF 47R X1)

Normally Closed
Common
Normally Open

Normally Closed
Common
Normally Open

Normally Closed
Common
Normally Open

Out
Return

TOC-625

Relay

Output

TOC-625

Relay

Output

TOC-625

Relay

Output

As standard the TOC-625 controller is equipped with two relay outputs. The function of these two relay

outputs can be user configured and is discussed in a later section. The relays are rated to operate 4A

non inductive loads. Typical wiring arrangements are indicated below and show typical methods to

protect the relays during installation.

External E-Stop

Fire Panel Interface

Example showing typical
connection to a fire system.

As standard the TOC-625 is equipped with three analogue outputs. By default these are configured

as 4-20mA current outputs. By request these can be set to 0-10V DC outputs during production. This

is a factory only setting. The following diagrams indicate the connections

+24V DC
0V DC
mA Sig 1
mA Sig 2
mA Sig 3

mA Analogue Output Interfaces

1

0V DC

Input 1
Input 2
Input 3

Chassis Gnd

TOC-625 Analogue
Outputs

Typical Interface Panel

Note this diagram shows the use of screened
cabling when interfacing signal cables. Signal
cables should be segregated from power and
control cables for best results.

18

28

TOC-625
DC SUPPLY
VOLTS

R (Ohms)
at Interface
Panel

200

800

Allowable
Operating
Region

Ώ

Ώ
Ώ
Ώ

Page 14 of 25

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Analogue Outputs (Voltage)

Testing Analogue Outputs

If requested at the time of ordering the TOC-625 can be supplied with its analogue outputs re-

configured as 0-10V DC. The following diagrams indicate the connections

+24V DC
0V DC
V Sig 1
V Sig 2
V Sig 3

0-10V Analogue Output Interfaces

1

0V DC
Input 1

Input 2
Input 3

Chassis Gnd

TOC-625 Analogue
Outputs

Typical Interface Panel

Note this diagram shows the use of screened cabling when interfacing signal cables.
Signal cables should be segregated from power and control cables for best results.

The operating system has a simulation mode for the analogue output channels. This allows the

commissioning engineer to force a signal output to prove correct interfacing at the host system.

release

á 50

PASSWORD

á 8

test

â 8

test

dec

test

inc

test

done
test

cancel

test

output 2

5 of 9

output 3

6 of 9

output 1

4 of 9

From Normal Operation press the function button until the display

alters to show ‘release button.

The system now requests a password. Enter 50 to enter the

Engineer Menu.

Press the function button until the required option, OUTPUT 1, 2 or

3 is displayed. Now hold down the button until prompted to

release.

In this example output 1 will be tested.

Press the button until TEST is indicated and hold until prompted to

release.

The display now shows a mV or mA output reading which can be

increased or decreased as desired during testing as follows (mA

output shown)..

output 1

4 of 9

output 1

release

ZERO

CLICK TO

CAL

CLICK TO

TEST

CLICK TO

Indicates each button
click will increase the
reading/output

Current
Reading

To decrease the
reading press and
hold the button.
The display
cycles through the
following options

The down arrow now
indicates each button press
will decrease the reading. In
a similar manner select done
when finished

Release the button when the
desired option is displayed

Page 15 of 25

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Putting into Service Test Schedule

In conclusion by following the steps discussed your checklist for putting into service should be:

1

2

3

4

5

6

7

8

9

10

11

Ensure the mains power supply is via a fused spur and installed in accordance with local

installation wiring regulations.

Check cable and glands are of suitable type for both the area of application and load carrying

capacity.

Ensure terminations via glands provide a positive seal.

Leave all interfaces unplugged and check installation cabling terminations following IGD

publication ref “Cable checks T625-700-920.PDF”.

Check the shipping TOC-625 SET UP REPORT to check how the controller and interfacing

detectors and nodes have been configured. Ensure that the detector addresses match the

document.

Plug in the connector 3 and power up the system. Check that all connected devices indicate

that they have power and are communicating correctly.

Allow at least 1 hour for the detectors to correctly warm up and stabilise.

During this period, if the relay outputs are being used check the cabling then plug in and test

using the TST RLY function the relay action.

During this period if the analogue outputs are being used check the cabling to connector 1 ,

plug in and test using the OUTPUT 1, 2 or 3 functions.

After warm up is complete use instrument air or Nitrogen as appropriate to check the detector

zero reading. Adjust if necessary (see later “zero and calibration function” section).

After warm up is complete use a suitable known calibration gas to check the detector calibration

reading. Adjust if necessary (see later “zero and calibration function” section).

Complete any site paperwork as necessary and instruct the site responsible person regarding

day to day operation (see later section “ user operation “).

Use the CHECK function to ensure detector channels are correctly set up and calibrated (see

section Addendum 1).

In the event that the controller needs amendment to set up follow the instructions in the following
sections.

a) Adding detectors or nodes to the controller or complete set up

b) Adding or changing alarm levels

c) Assigning relay outputs

d) Zero and Calibration Function (detectors)

e) Zero and Calibration Function (analogue outputs)

Page 16 of 25

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Adding detectors or nodes to the controller or complete set up

If you need to either:

1. Perform a complete new set up

2. Add or remove detectors from a system

3. Change the type of sensors connected to a system

Then presuming the system is correctly installed and cabled the process would be as follows:

1. Use the FIND command to discover connected devices and install them to the controller

2. Set up the required alarm levels and relay actions

3. Test using zero and calibration gases

The following dialogues describe each function to use

The FIND Command

find

1 of 9

find

1 of 9

find

Release

s=2 40%

checking

1 = 4101
found= 2

2 = 4101
found= 2

2 = 4101

Release

no

Release

yes

Release

saved=2

passed

As previously described enter password mode and enter password 50 to gain access to the

engineers menu. The first menu option (menu option 1 of 9) is the FIND menu. To run this option the

detectors must be correctly connected to the controller and displaying green power LED function as

a minimum (some of the green power LED’s may be flashing if detectors already have

communication.) The FIND function then works in the following manner

Press and hold button
until prompted to
release. The system
starts discovering
connected devices

Display indicates devices found so far

Display indicates % progress

When the discovery process is
complete the display indicates
how many sensors have been
found. The system also indicates
the first found address. Each
button press then indicates each
found device address in turn.

To store or abort the data press and
hold the button until prompted to
release. The first option is NO to
store data, pressing the button
changes this to YES to store data
and vice versa. With the desired
option displayed press and hold the
button until prompted to release.

If the YES option to store data
was selected then the number
of saved devices is shown on
screen and passed of fail to
indicate the status of the
update

1

2

3

4

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Once the correct number of devices (either detectors or nodes) have been found and saved

(installed). Then the alarm levels can be set in the following manner.

From the TOC-625 SET UP REPORT it can be seen that each connected and installed detector or

channel can have two alarm levels set. These can be different for each device. For example a two

channel system for Methane and Carbon Monoxide may have Alarm 1 level for Methane at 20%

LEL and Alarm 1 level for Carbon Monoxide set at 35ppm.

Channel 1

Address
Gas
Range
AL1
AL1 Type
AL1 Relay
AL2
AL2 Type
AL2 Relay
Analogue
Output
Channel

Channel 2

Address
Gas
Range
AL1
AL1 Type
AL1 Relay
AL2
AL2 Type
AL2 Relay
Analogue
Output
Channel

Channel 3

Address
Gas
Range
AL1
AL1 Type
AL1 Relay
AL2
AL2 Type
AL2 Relay
Analogue
Output
Channel

4101
Methane
100% LEL
20%
Rising Latch
1
50%
Rising Latch
2
C1

4102
CO
100 ppm
35
Rising Latch
1
55
Rising Latch
2
C2

Sales Order: S/36981 Client: A.N Other TOC-625 Set Up Report

Note in this example that either channel alarm level 1 sets off relay 1 on the controller once the

set threshold is exceeded. By default once the FIND function has been run and detectors

installed the alarm levels will be preset at 20 and 50 % of the detector or channels range and the

alarm action will be rising latching.

Alarm levels are set by the following method:

Page 18 of 25

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alarm 1

3 of 8

alarm 1

3 of 8

alarm 1
release

alarm 2

4 of 8

Alarm Level Set Up

As previously described enter password mode and enter password 100 to enter the user menu.

Press the button until either menu 3 or 4 is displayed and hold the button until prompted to release.

The set up sequence for the alarm level selected is as follows:

á 1

sensor

dec

test

inc

test

done
test

cancel

test

LEVEL

click to

release

TYPE

click to

SUMMARY

click to

RELAY

click to

EXIT

click to

To alter say alarm level 1
press and hold the
button on ALARM1
option until prompted to
release. Now select
which sensor or channel
you wish to set alarm
level 1 for.

This is the sensor number or channel number you
are selecting for which to enter alarm level 1.
Each button press increments the number. To
access more options press and hold the button
until prompted to release and the following menu
choices are available at each button press. Again
to select the desired option when displayed press
and hold the button until prompted to release.

Select to DECrease the channel numbers

Select to exit the sequence without making
changes

Select to INCrease the channel numbers

Select if the correct channel number is
displayed and you want to set the alarm
level

Each button press moves to the
next option. bottom line of display
scrolls “click to change selection”

To select an option press
and hold the button until
prompted to release.

á 20

level

Each button press increments the indicated alarm level.
access more options press and hold the button until prompted
to release and the following menu choices are available at
each button press. Again to select the desired option when
displayed press and hold the button until prompted to release.

To

dec

test

inc

test

done
test

cancel

test

Select to DECrease the alarm level

Select to exit the sequence without making
changes

Select to INCrease the alarm level

Select if the correct alarm level is displayed
and you want to store it onto the system.

Page 19 of 25

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LEVEL

click to

TYPE

click to

SUMMARY

click to

RELAY

click to

EXIT

click to

Once the alarm level has been set you then need to set the Alarm TYPE and decide which relay activates

once the set alarm level is breached. The following sequence continues from the previous page and

describes the set up sequences

To select an option press and hold
the button until prompted to release.

áL

select

á

select

â

select

âL

select

Bottom line indicates “select alarm type”
button press moves to the next option

Each

Rising Latching Alarm

Latching alarms
remain set until the
button is pressed to
reset the alarm. The
gas level must be
below the alarm level
threshold for the reset
to operate. This type of
alarm is typically used
in safety applications.
Where alarm is
required in response to
rising gas levels

Press and hold until
prompted to release to
select this option.

Rising Alarm

Rising alarms will
automatically reset
once the gas level falls
below the alarm
threshold. This type of
alarm is typically used
in control applications
where action is
required in response to
rising gas levels.

Press and hold until
prompted to release to
select this option.

Falling Latching Alarm

Latching alarms remain set
until the button is pressed
to reset the alarm. For a
falling alarm the gas level
must be above the alarm
level threshold for the reset
to operate. This type of
alarm is typically used in
safety applications for
Oxygen deficiency
monitoring where you are
monitoring for a falling
Oxygen level.

Press and hold until
prompted to release to
select this option.

Falling Alarm

Falling alarms will
automatically reset once
the gas level rises
above the alarm
threshold. This type of
alarm is typically used in
control applications
where action is required
in response to falling
gas level (typical in
Oxygen deficiency
applications).

Press and hold until
prompted to release to
select this option.

Rising and Falling Non Latching Alarms

Rising and Falling Latching Alarms

Alarm Set Point

Alarm Set Point

Alarm O/P On

Re-Set Input On

Alarm O/P Off

Re-Set Input Off

5% of Alarm Set PointAlarm Activates

Alarm Activates

10 Seconds

10 Seconds

Alarm Resets

Indicates pressing the front panel ‘jog wheel’ to cancel the alarm

Page 20 of 25

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LEVEL

click to

LEVEL

click to

ALARM2

04 OF 08

TYPE

click to

TYPE

click to

SUMMARY

click to

SUMMARY

click to

SUMMARY

click to

RELAY

click to

RELAY

click to

EXIT

click to

EXIT

click to

Once the alarm TYPE has been set you then need to set the RELAY output, that is deciding which relay

activates once the set alarm level is breached. The following sequence continues from the previous page

and describes the set up sequence

To select an option press and hold
the button until prompted to release.

To select an option press and hold the button until prompted to release.

á 1

relay

01=L20

áL R1

01=L20

áL R2

02=L20

áL R1

Each button press increments the indicated relay to activate.
To access more options press and hold the button until
prompted to release and the following menu choices are
available at each button press. Again to select the desired
option when displayed press and hold the button until
prompted to release.

dec

test

inc

test

done
test

cancel

test

Select to DECrease the relay number

Select to exit the sequence without making
changes

Select to INCrease the relay number

Select if the correct relay number is displayed
and you want to store it onto the system.

Selecting SUMMARY from this group of menu options allows you to see what has already been set up

In this example a two channel system has two alarm level 1's set up. When you enter the option

alarm level one settings for the channel are displayed. Click the button to return to the previous

menu options. To view alarm level 2 settings go back and select ALARM2 option. Note you only

view the summary one channel at a time.

Page 21 of 25

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CALIBRATIONS

MA

MACom

4.12

+24V DC
0V DC
mA Sig 1
mA Sig 2
mA Sig 3

mA Analogue Output Interfaces

1

TOC-625 Analogue
Outputs

The TOC-625 is equipped with three 4-20mA analogue outputs. By default these are configured so that

output 1 relates to input channel 1, output 2 is input channel 2 and output 3 is input channel 3. The TOC-

625 is shipped with these channels pre-calibrated. It should not normally be necessary to calibrate these

channels. The system has functions to allow zero, calibration and test of these channels as follows:

4-20mA Output Calibration and Test

The following sequence discusses calibration for

channel 1. The sequence is the same for each

channel. As indicated in the diagram connect a multi-

meter on its mA scale between 0V DC and the output

to be tested, in this case signal 1 (on connector 1).

As previously described enter password mode and enter password 50 to enter the engineer menu.

Press the button until either menu 3, 4 or 5 is displayed depending on the required output channel and

hold the button until prompted to release. The following sequence shows output 1 being calibrated as an

example.:

á 50

PASSWORD

output 1

4 of 9

ZERO

click to

CAL

click to

TEST

click to

DONE

click to

Each click of the button now cycles you through the available

menu options as follows. As with previous menu’s press and

hold the button to select the displayed option:

Select this option to zero the channel

Select this option to calibrate the channel

Select this option to return to the previous menu

Select this option to test the channel, this option forces the
output to whatever mA output is required.

Page 22 of 25

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4-20mA Output Zero Function

4-20mA Cal Zero Function

MA

MA

MA

MA

Com

Com

4.12

19.85

+24V DC
0V DC
mA Sig 1
mA Sig 2
mA Sig 3

+24V DC
0V DC
mA Sig 1
mA Sig 2
mA Sig 3

mA Analogue Output Interfaces

mA Analogue Output Interfaces

1

1

TOC-625 Analogue
Outputs

TOC-625 Analogue
Outputs

ZERO

click to

CAL

click to

From the menu previously
described select the zero option.

From the menu previously
described select the CAL option.

á 103

ZERO

á 105

CAL

The display now shows the current
‘setting’ for the channel zero, in this
case 103. Increasing this setting will
increase the indicated 4mA setting and
vice versa. Increase or decrease the
setting until the meter reads 4mA +/-

0.1mA then from the sub menu select
DONE (press and hold for sub menu
as previously described).

The display now shows the current
‘setting’ for the channel Calibration, in
this case 105. Increasing this setting
will increase the indicated 20mA setting
and vice versa. Increase or decrease
the setting until the meter reads 20mA
+/-0.1mA then from the sub menu
select DONE (press and hold for sub
menu as previously described).

Page 23 of 25

For best results fit a 220
Ohm resistor in series

For best results fit a 220
Ohm resistor in series

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This sequence first indicates if the
zero operation passed or failed, then
the new detector reading then the
option to end and return to the
engineer menu. This sequence
effectively allows the engineer to
observe the new detector zero point
before exiting.

Bottled Nitrogen or
Instrument grade zero air

Regulator to deliver a fixed
flowrate (typically between

0.5 to 1 L/min)

Hose delivers zero gas to the
detector. Note a test gas applicator
is usually required. In some cases
weather protection guards or the
detector itself may include a gas
applicator port. If not the correct
calibration gas adaptor must be
used.

co

0-100 ppm

ADDRESS

4101

CARBON MONOXIDE DETECTOR

Gas Detector ZERO Function

All gas detectors will require periodic ZERO and CALIBRATION. The calibration interval depends on a number of

environmental factors such as: temperature variance, exposure to wind chill, rain, humidity changes and vibration

to list a few. As a guide line gas detectors should be checked at least yearly. As with any measuring instrument if

calibration is not held over the intervening interval then a shorter calibration interval may be required.

Detectors should always be zeroed first and then calibrated. Alarms should be isolated during this process. A

normal calibration sequence would consist of:

1. Assess zero reading in pre-zero condition and record by applying a zero gas typically Nitrogen or Instrument air

2. Assess calibration point by applying a known calibration gas. and record

3. If the zero and calibration points are within +/-2% of range then take no further action. zeroing and calibrating a

detector that already reads correctly will not improve its performance. If either is out then proceed to step 4.

4. Apply a suitable zero gas and zero the channel, observe and record result.

5. Apply a known calibration gas and calibrate the channel, observe and record the result.

Notes

Do not rely on the ambient environment to provide a zero point, Nitrogen or Instrument air should always be used

as appropriate. If there is a background level of the target gas and a zero is performed then the zero point will not

be correctly set.

To Zero the detector enter password mode

as previously described and enter

password 100 to enter the user menu.

Select menu item 1 ZERO

The top line of the display shows the

current reading. The bottom line shows the

current option.

With zero gas flowing and the reading stable

press the button to select CONTINUE. Now

press and hold the button until prompted to

release to action the zero request.

zero

1 of 8

8 PPM

Abort

0 PPM

Continue

ZERO

PASSED

0 PPM

CLICK TO

The display shows the result of the zero request, note that the actual zero and

calibration values are stored on the individual detector heads. When carrying out a

zero or calibration the controller sends the request to the detector head for action

and monitors the result. This means that detectors can be supplied pre-calibrated

The reading is now displayed so the result of the zero request can be observed.

The reading should be stable. Click the button to return to the previous menu.

Repeat the sequence if you are not within +/-2% of zero.

Page 24 of 25

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This sequence first indicates if the
zero operation passed or failed, then
the new detector reading then the
option to end and return to the
engineer menu. This sequence
effectively allows the engineer to
observe the new detector zero point
before exiting.

Known Calibration
Gas to Traceable
standard.

Regulator to deliver a fixed
flowrate (typically between

0.5 to 1 L/min)

Hose delivers zero gas to the
detector. Note a test gas applicator
is usually required. In some cases
weather protection guards or the
detector itself may include a gas
applicator port. If not the correct
calibration gas adaptor must be
used.

co

0-100 ppm

ADDRESS

4101

CARBON MONOXIDE DETECTOR

Gas Detector CAL Function

Gas detectors must be calibrated with known calibration gases traceable to National Standards. As previously

discussed detectors require regular calibration. Calibration gases should have values chosen that either:

a) Are at the alarm set point to get maximum accuracy at this point

or

b) Are between 50 to 90% of the range of the detector. The detector measuring range will normally be marked on

the detector.

To CAL the detector enter password mode

as previously described and enter

password 100 to enter the user menu.

Select menu item 2 CAL

The top line of the display shows the current

reading. The bottom line shows the current

option.

With CAL gas flowing and the reading stable

press the button to select CONTINUE. Now

press and hold the button until prompted to

release to action the zero request.

CAL

2 of 8

55 PPM

Abort

55 PPM

Continue

CAL

PASSED

50 PPM

CLICK TO

The display shows the result of the cal request, note that the actual zero and

calibration values are stored on the individual detector heads. When carrying out a

zero or calibration the controller sends the request to the detector head for action

and monitors the result. This means that detectors can be supplied pre-calibrated

The reading is now displayed so the result of the cal request can be observed. The

reading should be stable. Click the button to return to the previous menu.

á 1

sensor

á 50

BOTTLE

Enter the channel number you wish to

calibrate.

Enter the calibration gas value, this will be

marked on the gas bottle and enter.

Page 25 of 25

Repeat this sequence if you
are not within +/-2% of the
gas bottle value.

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Additional Information for

TOC-630

Versions with GSM Module

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Introduction

When equipped with a GSM module the TOC-625 becomes a TOC-630.

In this mode of operation the TOC-630 operates in a different manner. As a TOC-630 the controller:

Accepts a pulse input from a gas meter and has additional software functions to provide, totalised
counts, account numbers, gas meter serial numbers etc

Controls a gas supply solenoid valve

Accepts a contact closure input from external safety devices such as gas detectors such that the
control solenoid is automatically turned off if the input signal is detected.

Is connected to a GSM module allowing remote SMS M2M functionality.

Whilst additional screen menu’s are available to provide additional diagnostic data any set up
changes required should be made via the IGD configurator software package.

It should be noted that changes to the set up away from default settings supplied can have
unintended consequences.

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TOC-630 BLOCK DIAGRAM

Gas Meter Typical of Elster

Type BKG4M with Pulse

Module IN-Z61

Supply Solenoid

Valve (Shown as

Mains Powered)

Gas Solenoid Fused Spur

GSM Module supplied Pre-wired

TOC-630

Fused Spur

Fused Spur’s for TOC-10 Gas Detectors

Alarm Loop For TOC-10 Gas Detectors

TOC-630

TOC-10 TOC-10

Gas Meter Pulse Output to TOC-630

Use Link Function To Group

TOC-10 alarm Function

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Electrical Details TOC-630 Figure 2

Front View

Cover Open

L N Enc nc

Mains Power

Connector

110/230V AC 50/60Hz

+24V DC
0V DC
Meter
Alarm
0V DC

Device Interfaces

RL

1

RL1

OR

Normally Closed
Common
Normally Open

0V DC
A
B
24V DC

RS485 Modbus
Comms Port
or IGD Configurator

3

2

1

0V DC

24V DC

~

~

A1

A1

A2

A2

Example fit protection
diodes when switching
external DC loads.

Example fit protection
supressors when switching
external AC loads typical
device Farnell Ref 1438460
(0.22uF 47R X1)

Normally Closed
Common
Normally Open

Normally Closed
Common
Normally Open

Serial GSM Interface

0V DC Tx Rx 24V DC

3

Supplied Pre-Wired

GSM Module

Note the Gas Meter input is typically IN-Z61 type
(magnetically operated reed switch) and is a sealed unit

Comm
NO

I/O
0V

I/O
0V

AL2 Link Link

TOC-10 TOC-10

Alarm function expects a normally open relay, closing on
alarm. The diagram shows TOC-10 modules interfaced using
the link function, refer to TOC-10 manual for full details

Note for TOC-10 up to 8 detectors can be connected using the link function so if one
goes into alarm, all linked detectors go into alarm. In this example one TOC-10 of the
linked group has its alarm 2 relay interfaced to the TOC-630.

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Additional Menu’s for Gas Metering.

The VIEW ALL Menu

If the controller is configured as a TOC-630 then additional menu’s are available to interrogate and test the
unit.

reading=3.350m3

1 of 15

VIEW ALL

4 of 9

gas supply=1

2 of 15

tel no 2=[phone]

5 of 15

account number=0100

7 of 15

gas detection=0

3 of 15

tel no 3=[phone]

6 of 15

tel no 1=[phone]

4 of 15

SERIAL NUMBER=GXF223454

8 of 15

INITIAL READING=0.050

9 of 15

INITIAL READING DATE=11.10.2010

10 of 15

This menu provides information only. Each button press displays the next data item. To adjust any of these
parameters requires access to IGD configurator software. In each case the top line of the display scrolls to
display the data.

Indicates current stored meter reading

Indicates the initial gas meter reading on installation.

Indicates current status of the gas supply,
1=Gas Solenoid On, 0=Gas Solenoid Off

Indicates current status of the gas detection,
1=Gas Detected, 0=Normal, no gas detected

This is the client account number and must match the account
number stored on the host PC running IGD TOC 630
communicator software.

This is the serial number of the gas meter on site.

Indicates the stored external
telephone numbers that the TOC­630 will accept commands from.
One of these numbers must be the
host PC system which remotely
collects data. The remaining two
numbers can be used for example
for remote engineer diagnostics
etc.

Indicates the date of the initial meter reading.

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PHYSICAL READING=1.550m3

11 of 15

PHYSICAL READING DATE=10.12.2012

12 of 15

METER SCALING 1 PULSE=0.01m3

13 of 15

METER ADDRESS=0

14 of 15

RELAY ADDRESS=0

15 of 15

TEST SMS

6 of 9

Next button press returns to main menu.

Indicates the last physical meter reading entered onto the
TOC-630. This reading is used to calculate billing.

Indicates the date on which the last physical meter
reading was taken.

Indicates the value for each incremental pulse from the
gas meter.

Indicates the address of the gas meter input, 0 indicates it
is a physical input on the TOC 630.

Indicates the address of the gas meter supply valve relay,
0 indicates it is a physical output on the TOC 630.

The VIEW ALL Menu.....continued

The TEST SMS Function

This diagnostic option sends a test SMS message to one of the three entered telephone numbers as
selected to prove communication function.

á 1

tel num

SENDING

PROG = 2

SENDING

PASSED

Each click of the button increments the stored telephone number to

use. The sub menu can be used to decrease the displayed number,

cancel the action or accept the number. A test SMS message is then

sent to the selected phone number (1,2 or 3 as stored). A progress

indicator is displayed as the message is sent and a result as either

Passed or Failed is indicated.

dec

test

inc

test

done
test

cancel

test

Release the button when the
desired option is displayed

Sub Menu

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The GSM Diagnostics Function

GSM DIAG

5 of 9

SIG=36%
L57 E=0

REG !UK
L85 E=0

VODAPHONE

L135 E=0

MC55i

L149 E=0

01.201

L175 E=0

89460800
L225 E=0

This function displays diagnostic data for the GSM modem. Each button press advances through the available
data display options as follows:

Displays the modem signal strength which should ideally be better than
50%. the L number indicates how many command loops have been
transmitted between the modem and the TOC-630. The E number is the
error rate which should be zero. Note this data is shown on the bottom line
of each display item.

Indicates where the SIM is registered, the ! symbol is a NOT indicator so in
this example indicates NOT UK registered (roaming)

Indicates currently connected network.

Indicates the connected modem model

Indicates the modem software version

Indicates the last eight digits of the SIM card number

Press and hold after the last menu item until
prompted to return to the main menu.

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Addendum 1

CHECK and FIX Functions

CHECK

5 OF 11

FIX

6 OF 11

á 1

SENSOR

á 1

SENSOR

The Check Function can be used to validate that a connected gas detector
channel is correctly set up and calibrated. Select the function from the (50)
engineer menu and you are prompted for which channel to check. The TOC­625 then runs an automated sequence where it checks that the range matches
the calibration gas value used and that zero and calibration voltages are
consistent. Once the check is complete each press of the button displays each
data item checked on the panel. If the set up data item is correct the backlight
stays green otherwise it is highlighted red to show it is in error or yellow for a
warning. Any errors can be corrected by using the FIX menu item.

Select Sensor

Select Sensor

Select Sensor

CHECK

PASSED

CHECK

FAILED

0.0

CONC

0.0

CONC

0.99

VOLTS

0.99

VOLTS

0.99V
ZERO

0.99V
ZERO

50

BOTTLE

50

BOTTLE

1.75V
CAL

2.30V
CAL

100

RANGE

100

RANGE

Press button to advance displayed data

Press button to advance displayed data

Shows Concentration
and detector volts now

Shows Concentration
and detector volts now

Stored Zero
Volts

Stored Zero
Volts

Stored Cal
Volts

Stored Cal
Volts are
too high
and need
correcting

Entered bottle value and
channel range.

Entered bottle value and
channel range.

Use the FIX menu option to
correct any errors

The FIX option will automatically ‘repair’ any set up issues relating
to a channel that has failed sensor CHECK.

In the example shown above where the channel fails due to the
cal voltage being too high; FIX will set the gain setting back to a
sensible default value.

After running FIX on a channel its calibration should be re­checked with a known calibration gas.

www.sensors.ltd.ukA Division of International Gas Detectors

Tel: [phone]

Fax: [phone]

Email: [e-mail]